CN114999815A - Compression molding inductor and preparation method and application thereof - Google Patents

Compression molding inductor and preparation method and application thereof Download PDF

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CN114999815A
CN114999815A CN202210835351.9A CN202210835351A CN114999815A CN 114999815 A CN114999815 A CN 114999815A CN 202210835351 A CN202210835351 A CN 202210835351A CN 114999815 A CN114999815 A CN 114999815A
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powder
inductor
amorphous powder
magnetic powder
iron
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胡江豪
金崭凡
陈胜齐
娄海飞
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Hengdian Group DMEGC Magnetics Co Ltd
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Hengdian Group DMEGC Magnetics Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15308—Amorphous metallic alloys, e.g. glassy metals based on Fe/Ni
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15341—Preparation processes therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/147—Alloys characterised by their composition
    • H01F1/153—Amorphous metallic alloys, e.g. glassy metals
    • H01F1/15358—Making agglomerates therefrom, e.g. by pressing
    • H01F1/15366—Making agglomerates therefrom, e.g. by pressing using a binder
    • H01F1/15375—Making agglomerates therefrom, e.g. by pressing using a binder using polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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  • Chemical & Material Sciences (AREA)
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  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

The invention provides a compression molding inductor and a preparation method and application thereof, wherein the preparation method comprises the following steps: (1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; (2) winding a conductor coil, and fixing the obtained conductor coil on a lead frame to obtain a lead combination; (3) placing the lead combination obtained in the step (2) on the T-core obtained in the step (1) in a sleeving manner, filling magnetic powder, and then performing compression molding to obtain a semi-finished inductor; (4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; wherein, the step (1) and the step (2) are not in sequence. The preparation method provided by the invention solves the problem of coil positioning, reduces the strength requirement on the T-core, simplifies the preparation process and reduces the production cost.

Description

Compression molding inductor and preparation method and application thereof
Technical Field
The invention belongs to the technical field of inductors, relates to a compression molding inductor, and particularly relates to a compression molding inductor and a preparation method and application thereof.
Background
The inductor is one of the basic components constituting an electronic circuit, and is widely used in electronic products such as mobile phones, computers, and the like. With the rapid development of electronic technology, especially the overall popularization of consumer electronics, the market puts higher and higher demands on the miniaturization and high performance of the inductor, the miniaturization and high performance of the inductor also have high demands on the precision of production equipment, and the investment cost is increased accordingly. Therefore, it is urgent to improve the production efficiency and save the cost.
Inductors can be roughly classified into three types according to their processing techniques: low-temperature co-fired laminated inductors, wire-wound inductors and compression-molded inductors. The magnetic core material used in the low-temperature co-fired laminated inductor production process is ferrite, and the saturation characteristic of the ferrite is poor, so that the field of high-performance requirements cannot be met; the winding inductance is formed by winding a coil on a magnetic core, the process has high requirement on dimensional accuracy, small-sized products are difficult to prepare, and the problems of low yield, high cost and the like can be met even if the process is feasible; molded inductors often suffer from inaccurate coil positioning, coil deflection and deformation.
CN 202183292U discloses an improved integrally formed inductor, which comprises a coil, a magnetic solid body and two electrode pins, wherein the coil is embedded in the magnetic solid body, one end of each electrode pin is a first end, the other end of each electrode pin is a second end, the first ends of the two electrode pins are respectively embedded in the magnetic solid body, and the two electrode pins are respectively welded with two ends of the coil. The inductor adopts a coil spot welding post-molding process, and the coil is not positioned in the body, so that the coil is easy to deviate and deform during molding, and great influence is brought to product characteristics and quality.
CN 108648901A discloses a method for manufacturing an inductor, which belongs to an integrated winding inductor, and the inductor is manufactured by firstly pressing magnetic powder into T-core with a certain shape, then winding the T-core, and processing the T-core by a series of processes such as hot pressing, roll spraying, laser, electroplating and the like. Although the manufacturing method adopts a winding process, the coil is firstly wound on the T-core, and the deformation of the coil can be reduced due to the protection of the T-core during hot pressing, the coil needs to be wound on the T-core firstly, and the winding needs large tension (the coil can reach the size specification required by design under certain tension), so that the T-core is required to have high strength (the winding needs to be carried out on the T-core) and size precision (the coil can exceed the body due to poor precision), and particularly, the requirements on the equipment precision and powder characteristics (such as sphericity, fluidity and the like) can be higher along with the reduction of the product size, and the manufacturing method is not suitable for the production of inductors with smaller sizes.
Therefore, how to provide a method for manufacturing an inductor solves the problem of coil positioning, reduces the strength requirement on the T-core, simplifies the manufacturing process, reduces the production cost, and becomes a problem which needs to be solved urgently by technical personnel in the field at present.
Disclosure of Invention
The invention aims to provide a compression molding inductor and a preparation method and application thereof, and the preparation method solves the problem of coil positioning, reduces the strength requirement on T-core, simplifies the preparation process and reduces the production cost.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the invention provides a method for preparing a compression molding inductor, which comprises the following steps:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core;
(2) winding a conductor coil, and fixing the obtained conductor coil on a lead frame to obtain a lead combination;
(3) placing the lead combination obtained in the step (2) on the T-core obtained in the step (1) in a sleeving manner, filling magnetic powder, and then performing compression molding to obtain a semi-finished inductor;
(4) and (4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor.
Wherein, the step (1) and the step (2) are not in sequence.
Aiming at the defects that the coil can not be accurately positioned to cause the deviation and deformation of the formed coil and the problem that the integral winding inductor has high requirement on the strength of the T-core, the preparation method provided by the invention adopts the steps of winding the conductor coil in advance, sleeving the conductor coil on the T-core, then carrying out compression molding, and finally obtaining the finished product inductor through a series of subsequent treatments.
Preferably, the magnetic powder in step (1) comprises amorphous powder and/or alloy powder, and further preferably amorphous powder and alloy powder.
Preferably, the amorphous powder includes any one of or a combination of at least two of iron-based amorphous powder, nickel-based amorphous powder, zirconium-based amorphous powder, aluminum-based amorphous powder or cobalt-based amorphous powder, and typical but non-limiting combinations include a combination of iron-based amorphous powder and nickel-based amorphous powder, a combination of nickel-based amorphous powder and zirconium-based amorphous powder, a combination of zirconium-based amorphous powder and aluminum-based amorphous powder, a combination of aluminum-based amorphous powder and cobalt-based amorphous powder, a combination of iron-based amorphous powder, nickel-based amorphous powder and zirconium-based amorphous powder, a combination of nickel-based amorphous powder, zirconium-based amorphous powder and aluminum-based amorphous powder, or a combination of zirconium-based amorphous powder, aluminum-based amorphous powder and cobalt-based amorphous powder.
Preferably, the alloy powder includes any one or a combination of at least two of iron-nickel alloy powder, iron-silicon-aluminum alloy powder or iron-silicon-chromium alloy powder, and typical but non-limiting combinations include a combination of iron-nickel alloy powder and iron-silicon alloy powder, a combination of iron-silicon alloy powder and iron-silicon-aluminum alloy powder, a combination of iron-silicon-aluminum alloy powder and iron-silicon-chromium alloy powder, a combination of iron-nickel alloy powder, iron-silicon alloy powder and iron-silicon-aluminum alloy powder, or a combination of iron-silicon alloy powder, iron-silicon-aluminum alloy powder and iron-silicon-chromium alloy powder.
In the invention, the amorphous powder has large particles, low loss, high hardness and high magnetic conductivity; the alloy powder has small particles and low hardness, and can fill the internal gaps of the amorphous powder, so that the density of the product is further improved, and the magnetic conductivity of the product is further improved.
Preferably, the mass ratio of the amorphous powder to the alloy powder is (4-5): (5-6), and may be, for example, 4:5, 4.2:5.2, 4.4:5.4, 4.6:5.6, 4.8:5.8 or 5:6, but not limited to the enumerated values, and other values not enumerated within the numerical range are also applicable.
Preferably, the mixing of step (1) comprises mixing magnetic powder and a binder.
Preferably, the adhesive comprises an epoxy resin.
Preferably, the binder is present in an amount of 1 to 5% by mass, for example 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5% or 5% by mass, based on the total mass of the blend, but is not limited to the recited values, and other values not recited within this range are equally applicable.
Preferably, the average particle size of the granules obtained by the granulation in the step (1) is 40-300 meshes, such as 40 meshes, 60 meshes, 80 meshes, 100 meshes, 120 meshes, 140 meshes, 160 meshes, 180 meshes, 200 meshes, 220 meshes, 240 meshes, 260 meshes, 280 meshes or 300 meshes, but the average particle size is not limited to the listed values, and other values not listed in the range of the values are also applicable.
Preferably, the granulating in the step (1) further comprises drying the obtained granules.
Preferably, the temperature of the drying is 40-60 ℃, for example 40 ℃, 42 ℃, 44 ℃, 46 ℃, 48 ℃, 50 ℃, 52 ℃, 54 ℃, 56 ℃, 58 ℃ or 60 ℃, but is not limited to the recited values, and other values not recited in the range of values are also applicable.
Preferably, the drying time is 1 to 3 hours, for example, 1 hour, 1.2 hours, 1.4 hours, 1.6 hours, 1.8 hours, 2 hours, 2.2 hours, 2.4 hours, 2.6 hours, 2.8 hours or 3 hours, but is not limited to the recited values, and other values not recited in the range of the values are also applicable.
Preferably, the pressure applied in the pressing in the step (1) is 5-7T/cm 2 For example, it may be 5T/cm 2 、5.2T/cm 2 、5.4T/cm 2 、5.6T/cm 2 、5.8T/cm 2 、6T/cm 2 、6.2T/cm 2 、6.4T/cm 2 、6.6T/cm 2 、6.8T/cm 2 Or 7T/cm 2 However, the numerical values recited are not intended to be limiting, and other numerical values not recited within the numerical range may be equally applicable.
Preferably, the curing temperature in step (1) is 200 ℃ and 280 ℃, and may be, for example, 200 ℃, 205 ℃, 210 ℃, 215 ℃, 220 ℃, 225 ℃, 230 ℃, 235 ℃, 240 ℃, 245 ℃, 250 ℃, 255 ℃, 260 ℃, 265 ℃, 270 ℃, 275 ℃ or 280 ℃, but is not limited to the recited values, and other non-recited values within the range are also applicable.
Preferably, the curing time in step (1) is 5-20min, such as 5min, 6min, 7min, 8min, 9min, 10min, 11min, 12min, 13min, 14min, 15min, 16min, 17min, 18min, 19min or 20min, but is not limited to the recited values, and other values not recited in the range of values are also applicable.
Preferably, the curing pressure of step (1) is 4-6T/cm 2 For example, it may be 4T/cm 2 、4.2T/cm 2 、4.4T/cm 2 、4.6T/cm 2 、4.8T/cm 2 、5T/cm 2 、5.2T/cm 2 、5.4T/cm 2 、5.6T/cm 2 、5.8T/cm 2 Or 6T/cm 2 However, the numerical values are not limited to the numerical values listed, and other numerical values not listed in the numerical range are also applicable.
Preferably, the conducting wire adopted by the conductor coil in the step (2) comprises a copper wire.
Preferably, the cross-section of the wire comprises a circle, an ellipse or a rectangle.
Preferably, the fixing in step (2) includes welding.
Preferably, the material of the magnetic powder in the step (3) is the same as that of the magnetic powder in the step (1).
Preferably, the temperature for the compression molding in step (3) is 50 to 300 ℃, and may be, for example, 50 ℃, 60 ℃, 80 ℃, 100 ℃, 120 ℃, 140 ℃, 160 ℃, 180 ℃, 200 ℃, 220 ℃, 240 ℃, 260 ℃, 280 ℃ or 300 ℃, but is not limited to the recited values, and other values not recited in the range of the values are also applicable.
In the invention, the compression molding temperature needs to be controlled within a reasonable range. When the temperature is lower than 50 ℃, the epoxy resin monomer cannot be fully melted, the flowability is poor, the curing rate is low, and the utilization is influenced; when the temperature is higher than 300 ℃, the epoxy resin is easily decomposed, thereby breaking the crosslinking between the resins.
Preferably, the compression molding time in step (3) is 1-10min, such as 1min, 2min, 3min, 4min, 5min, 6min, 7min, 8min, 9min or 10min, but not limited to the recited values, and other values not recited in the range of the recited values are also applicable.
Preferably, the temperature of the heat treatment in step (4) is 100-.
Preferably, the heat treatment time in step (4) is 0.5-10h, such as 0.5h, 1h, 2h, 3h, 4h, 5h, 6h, 7h, 8h, 9h or 10h, but not limited to the recited values, and other values not recited in the range of values are also applicable.
Preferably, the insulation treatment in step (4) includes spraying an insulation layer on the surface of the inductor and curing.
Preferably, the thickness of the insulating layer is 8 to 12 μm, and may be, for example, 8 μm, 8.5 μm, 9 μm, 9.5 μm, 10 μm, 10.5 μm, 11 μm, 11.5 μm or 12 μm, but is not limited to the values listed, and other values not listed in this range of values are also applicable.
Preferably, the bending process in step (4) includes bending the lead frame from which the inductor is extended.
As a preferred technical solution of the first aspect of the present invention, the preparation method comprises the steps of:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; the magnetic powder comprises amorphous powder and alloy powder, and the amorphous powder comprises iron-based amorphous powder and nickelAny one or combination of at least two of base amorphous powder, zirconium-base amorphous powder, aluminum-base amorphous powder or cobalt-base amorphous powder, wherein the alloy powder comprises any one or combination of at least two of iron-nickel alloy powder, iron-silicon-aluminum alloy powder or iron-silicon-chromium alloy powder, and the mass ratio of the amorphous powder to the alloy powder is (4-5) to (5-6); the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 1-5% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 40-300 meshes; the granulation also comprises drying the obtained granules for 1-3h at 40-60 ℃; the pressure applied by the pressing is 5-7T/cm 2 (ii) a The curing temperature is 200-280 ℃, the curing time is 5-20min, and the applied pressure is 4-6T/cm 2 ；
(2) Winding a conductor coil by using a copper wire as a lead, and welding the obtained conductor coil to a lead frame to obtain a lead combination; the cross section of the wire comprises a circle, an ellipse or a rectangle;
(3) putting the lead combination obtained in the step (2) on the T-core obtained in the step (1) in a sleeving manner, filling magnetic powder, and then performing compression molding at 50-300 ℃ for 1-10min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; the temperature of the heat treatment is 100-250 ℃, and the time is 0.5-10 h; the insulation treatment comprises spraying 8-12 μm insulation layer on the surface of the inductor and curing; and the bending treatment comprises bending the lead frame extending out of the inductor.
Wherein, the step (1) and the step (2) are not in sequence.
In a second aspect, the invention provides a compression molding inductor prepared by the preparation method of the first aspect.
In a third aspect, the invention provides an application of the molded inductor according to the second aspect in an electronic product.
Compared with the prior art, the invention has the following beneficial effects:
aiming at the defects that the coil can not be accurately positioned to cause the deviation and deformation of the formed coil and the problem that the integral winding inductor has high requirement on the strength of the T-core, the preparation method provided by the invention adopts the steps of winding the conductor coil in advance, sleeving the conductor coil on the T-core, then carrying out compression molding, and finally obtaining the finished product inductor through a series of subsequent treatments.
Drawings
Fig. 1 is a flow chart of a method for manufacturing a compression molding inductor according to the present invention.
Detailed Description
The technical solution of the present invention is further explained by the following embodiments. It should be understood by those skilled in the art that the examples are only for the understanding of the present invention and should not be construed as the specific limitations of the present invention.
Example 1
The embodiment provides a compression molding inductor and a preparation method thereof, as shown in fig. 1, the preparation method includes the following steps:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; the magnetic powder comprises iron-based amorphous powder and iron-nickel alloy powder, and the mass ratio of the iron-based amorphous powder to the iron-nickel alloy powder is 4: 5; the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 2% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 200 meshes; the granulation also comprises drying the obtained granules for 2 hours at 50 ℃; the applied pressure of the pressing is 6T/cm 2 (ii) a The curing temperature is 240 ℃, the curing time is 10min, and the applied pressure is 5T/cm 2 ；
(2) Winding a conductor coil by taking a copper wire with a circular cross section as a lead, and welding the obtained conductor coil to a lead frame to obtain a lead combination;
(3) putting the lead combination obtained in the step (2) on the T-core obtained in the step (1), putting the lead combination into a die cavity, filling magnetic powder, and then performing compression molding at 150 ℃ for 5min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; the heat treatment is carried out in an oven at 180 ℃ for 5 hours; the insulation treatment comprises spraying 10 μm of insulation layer on the surface of the inductor and curing; and the bending treatment comprises the step of bending the lead frame extending out of the inductor by adopting a bending machine.
Example 2
The embodiment provides a compression molding inductor and a preparation method thereof, and as shown in fig. 1, the preparation method comprises the following steps:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; the magnetic powder comprises nickel-based amorphous powder and ferrosilicon powder, and the mass ratio of the nickel-based amorphous powder to the ferrosilicon powder is 5: 6; the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 1% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 40 meshes; the granulation also comprises drying the obtained granules for 3 hours at 40 ℃; the pressing pressure is 5T/cm 2 (ii) a The curing temperature is 200 deg.C, the curing time is 20min, and the applied pressure is 4T/cm 2 ；
(2) Winding a conductor coil by using a copper wire with an oval cross section as a lead, and welding the obtained conductor coil to a lead frame to obtain a lead combination;
(3) sleeving the lead combination obtained in the step (2) on the T-core obtained in the step (1), placing the lead combination in a die cavity, filling magnetic powder, and then performing compression molding at 50 ℃ for 10min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; the heat treatment is carried out in an oven at the temperature of 100 ℃ for 10 hours; the insulation treatment comprises spraying an 8-micron insulation layer on the surface of the inductor and curing; and the bending treatment comprises the step of bending the lead frame extending out of the inductor by adopting a bending machine.
Example 3
The embodiment provides a compression molding inductor and a preparation method thereof, as shown in fig. 1, the preparation method includes the following steps:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; the magnetic powder comprises zirconium-based amorphous powder and iron-silicon-aluminum alloy powder, and the mass ratio of the zirconium-based amorphous powder to the iron-silicon-aluminum alloy powder is 5: 5; the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 5% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 300 meshes; the granulation also comprises drying the obtained granules for 1h at 60 ℃; the pressing pressure is 7T/cm 2 (ii) a The curing temperature is 280 ℃, the curing time is 5min, and the applied pressure is 6T/cm 2 ；
(2) Winding a conductor coil by taking a copper wire with a rectangular cross section as a lead, and welding the obtained conductor coil to a lead frame to obtain a lead combination;
(3) sleeving the lead combination obtained in the step (2) on the T-core obtained in the step (1), placing the lead combination in a die cavity, filling magnetic powder, and then performing compression molding at 300 ℃ for 1min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; the heat treatment is carried out in an oven at the temperature of 250 ℃ for 0.5 h; the insulation treatment comprises spraying an insulation layer of 12 mu m on the surface of the inductor and curing; and the bending treatment comprises the step of bending the lead frame extending out of the inductor by adopting a bending machine.
Example 4
The present embodiment provides a compression molding inductor and a method for manufacturing the same, wherein the method is the same as that of embodiment 1 except that the temperature of the compression molding in step (3) is reduced to 80 ℃, and thus the details are not repeated herein.
Compared with example 1, in this example, due to the low temperature of the compression molding, the epoxy resin monomer cannot be fully melted, the flowability is poor, and the curing rate is low, which affects the operation.
Example 5
The present embodiment provides a compression molding inductor and a method for manufacturing the same, wherein the method is the same as that of embodiment 1 except that the temperature of the compression molding in step (3) is increased to 250 ℃, and thus the details are not repeated herein.
In this example, the epoxy resin was easily decomposed due to an excessively high temperature for press molding, compared to example 1, and the crosslinking action between the resins was broken.
Example 6
This embodiment provides a compression molding inductor and a method for manufacturing the same, wherein the steps and conditions are the same as those in embodiment 1 except that the temperature of the heat treatment in step (4) is reduced to 80 ℃.
In this example, the strength of the inductor is significantly reduced due to the excessively low temperature of the heat treatment, compared to example 1.
Example 7
This embodiment provides a compression molding inductor and a method for manufacturing the same, wherein the steps and conditions are the same as those in embodiment 1 except that the temperature of the heat treatment in step (4) is increased to 300 ℃, and thus the details are not repeated herein.
In this example, the epoxy resin was easily decomposed due to the excessively high temperature of the heat treatment, compared to example 1, and the crosslinking action between the resins was broken.
Comparative example 1
The comparative example provides a compression molding inductor and a preparation method thereof, and the preparation method specifically comprises the following steps:
(1) magnetic powder is utilized to obtain T-core through mixing, granulation, pressing and solidification in sequence; the magnetic powder comprises iron-based amorphous powder and iron-nickel alloy powder, and the mass ratio of the iron-based amorphous powder to the iron-nickel alloy powder is 4: 5; the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 2% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 200 meshes; the granulation also comprises the step ofDrying the granules for 2 hours at 50 ℃; the applied pressure of the pressing is 6T/cm 2 (ii) a The curing temperature is 240 ℃, the curing time is 10min, and the applied pressure is 5T/cm 2 ；
(2) Taking a copper wire with a circular cross section as a lead wire to directly wind a conductor coil on the T-core obtained in the step (1), welding the conductor coil on a lead frame, placing the conductor coil in a die cavity, filling magnetic powder, and then performing compression molding at 150 ℃ for 5min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(3) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (2) to obtain a finished inductor; the heat treatment is carried out in an oven at 180 ℃ for 5 hours; the insulation treatment comprises spraying 10 μm of insulation layer on the surface of the inductor and curing; and the bending treatment comprises the step of bending the lead frame extending out of the inductor by adopting a bending machine.
Compared with the embodiment 1, the comparative example does not wind the conductor coil in advance and then sleeve the conductor coil on the T-core, but directly winds the conductor coil on the T-core, and although the process can also solve the problem of coil positioning, the requirement on the strength of the T-core is high, otherwise, the T-core is easy to break in the winding process.
The inductance characteristics of the compression molded inductors obtained in examples 1 to 7 and comparative example 1 were measured and the results are shown in table 1:
TABLE 1
Figure BDA0003747732180000121
Figure BDA0003747732180000131
In the above table, the inductance value under 1M and 1V is measured by using the inductance measuring instrument, the inductance value under 4.6A is measured by using a matched direct current source and direct current, and the DCR is measured by using the DCR ammeter.
Therefore, aiming at the defects that the coil can not be accurately positioned to cause the deviation and deformation of the formed coil and the problem that the integral winding inductor has high requirement on the strength of the T-core, the preparation method provided by the invention adopts the steps of winding the conductor coil in advance, sleeving the conductor coil on the T-core, then carrying out compression molding, and finally obtaining the finished inductor through a series of subsequent treatments.
The applicant declares that the above description is only a specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and it should be understood by those skilled in the art that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are within the scope and disclosure of the present invention.

Claims (10)

1. A preparation method of a compression molding inductor is characterized by comprising the following steps:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core;
(2) winding a conductor coil, and fixing the obtained conductor coil on a lead frame to obtain a lead combination;
(3) placing the lead combination obtained in the step (2) on the T-core obtained in the step (1) in a sleeving manner, filling magnetic powder, and then performing compression molding to obtain a semi-finished inductor;
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor;
wherein, the step (1) and the step (2) are not in sequence.
2. The production method according to claim 1, wherein the magnetic powder of step (1) comprises an amorphous powder and/or an alloy powder, and is further preferably an amorphous powder and an alloy powder;
preferably, the amorphous powder comprises any one of iron-based amorphous powder, nickel-based amorphous powder, zirconium-based amorphous powder, aluminum-based amorphous powder or cobalt-based amorphous powder or a combination of at least two of the two;
preferably, the alloy powder comprises any one or a combination of at least two of iron-nickel alloy powder, iron-silicon-aluminum alloy powder or iron-silicon-chromium alloy powder;
preferably, the mass ratio of the amorphous powder to the alloy powder is (4-5) to (5-6).
3. The production method according to claim 1 or 2, wherein the compounding of step (1) comprises mixing a magnetic powder and a binder;
preferably, the binder comprises an epoxy resin;
preferably, the mass of the binder accounts for 1-5% of the total mass of the mixed material.
4. The method according to any one of claims 1 to 3, wherein the average particle size of the granules obtained by the granulation in the step (1) is 40 to 300 meshes;
preferably, the granulating in the step (1) further comprises drying the obtained granules;
preferably, the drying temperature is 40-60 ℃;
preferably, the drying time is 1-3 h;
preferably, the pressure applied in the pressing in the step (1) is 5-7T/cm 2 ；
Preferably, the temperature for curing in the step (1) is 200-280 ℃;
preferably, the curing time of the step (1) is 5-20 min;
preferably, the curing pressure of step (1) is 4-6T/cm 2 。
5. The method according to any one of claims 1 to 4, wherein the conductive wire used for the conductive coil of step (2) comprises a copper wire;
preferably, the cross-section of the wire comprises a circle, an ellipse, or a rectangle;
preferably, the fixing in step (2) includes welding.
6. The method according to any one of claims 1 to 5, wherein the magnetic powder in step (3) is made of the same material as the magnetic powder in step (1);
preferably, the temperature for compression molding in the step (3) is 50-300 ℃;
preferably, the time for the compression molding in the step (3) is 1-10 min.
7. The method according to any one of claims 1 to 6, wherein the temperature of the heat treatment in step (4) is 100 ℃ to 250 ℃;
preferably, the time of the heat treatment in the step (4) is 0.5-10 h;
preferably, the insulation treatment in the step (4) comprises spraying an insulation layer on the surface of the inductor and curing;
preferably, the thickness of the insulating layer is 8-12 μm;
preferably, the bending process in step (4) includes bending the lead frame from which the inductor is extended.
8. The method of any one of claims 1 to 7, comprising the steps of:
(1) sequentially mixing, granulating, pressing and curing magnetic powder to obtain T-core; the magnetic powder comprises amorphous powder and alloy powder, the amorphous powder comprises any one or the combination of at least two of iron-based amorphous powder, nickel-based amorphous powder, zirconium-based amorphous powder, aluminum-based amorphous powder or cobalt-based amorphous powder, the alloy powder comprises any one or the combination of at least two of iron-nickel alloy powder, iron-silicon-aluminum alloy powder or iron-silicon-chromium alloy powder, and the mass ratio of the amorphous powder to the alloy powder is (4-5): (5-6); the mixed material comprises mixed magnetic powder and epoxy resin, and the mass of the epoxy resin accounts for 1-5% of the total mass of the mixed material; the average particle size of the granules obtained by granulation is 40-300 meshes; the granulation also comprises drying the obtained granules for 1-3h at 40-60 ℃; the pressure applied by the pressing is 5-7T/cm 2 (ii) a The curing temperature is 200-280 ℃, the curing time is 5-20min, and the applied pressure is 4-6T/cm 2 ；
(2) Winding a conductor coil by using a copper wire as a lead, and welding the obtained conductor coil to a lead frame to obtain a lead combination; the cross section of the wire comprises a circle, an ellipse or a rectangle;
(3) putting the lead combination obtained in the step (2) on the T-core obtained in the step (1) in a sleeving manner, filling magnetic powder, and then performing compression molding at 50-300 ℃ for 1-10min to obtain a semi-finished inductor; the material of the magnetic powder is the same as that of the magnetic powder in the step (1);
(4) sequentially carrying out heat treatment, insulation treatment and bending treatment on the semi-finished inductor obtained in the step (3) to obtain a finished inductor; the temperature of the heat treatment is 100-250 ℃, and the time is 0.5-10 h; the insulation treatment comprises spraying 8-12 μm insulation layer on the surface of the inductor and curing; the bending treatment comprises bending the lead frame extending out of the inductor;
wherein, the step (1) and the step (2) are not in sequence.
9. A compression molded inductor produced by the production method according to any one of claims 1 to 8.
10. Use of a molded inductor according to claim 9 in an electronic product.
CN202210835351.9A 2022-07-15 2022-07-15 Compression molding inductor and preparation method and application thereof Pending CN114999815A (en)

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TWI685860B (en) * 2019-09-20 2020-02-21 達方電子股份有限公司 Inductor device and method of fabricating the same
CN112397295A (en) * 2020-09-25 2021-02-23 宁波中科毕普拉斯新材料科技有限公司 Manufacturing method of integrally formed inductor
CN112582134A (en) * 2019-09-30 2021-03-30 昆山磁通新材料科技有限公司 Preparation method of high-reliability molded inductor and molded inductor thereof
CN114050036A (en) * 2021-11-24 2022-02-15 横店集团东磁股份有限公司 Integrally-formed cup-core inductor and preparation method thereof
CN114334428A (en) * 2020-10-30 2022-04-12 宁波磁性材料应用技术创新中心有限公司 Manufacturing method of integrally-formed molded inductor

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Publication number Priority date Publication date Assignee Title
CN105845423A (en) * 2016-06-17 2016-08-10 深圳市固电电子有限公司 Manufacturing method of integrated inductor and integrated inductor manufactured thereby
TWI685860B (en) * 2019-09-20 2020-02-21 達方電子股份有限公司 Inductor device and method of fabricating the same
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